System and method for the remanufacturing of a sealed module

ABSTRACT

A system and method is provided for opening a sealed engine control module in which the module includes a substrate bent around and sealed to a central housing. In one aspect of the invention, the housing is machined around its perimeter, without damaging the substrate, to expose the sealing bead. The sealing bead is disrupted by cutting a groove in the bead, in one embodiment. The modified module is placed within an opening fixture that supports the substrate against buckling or folding while the substrate is unbent about the housing. In another aspect of the invention, a handling support can be attached to the unbent substrate to prevent buckling or folding while the circuit board supported by the substrate is evaluated or modified, and while the substrate is being transported. A closing fixture is also contemplated that supports the substrate while applying a force to fold or close the substrate about a new housing.

This application is a division of application Ser. No. 09/298,224, filedApr. 23, 1999 now U.S. Pat. No. 6,192,570.

BACKGROUND OF THE INVENTION

The present invention concerns the remanufacture of electronic controlmodules, such as for use with electronically controlled engines. Inparticular, the invention concerns a system and method for opening asealed module and resealing the module after servicing the internalcomponents.

Most modern internal combustion engines have some form for electroniccontroller that governs the operation of the engine. In the case oflarger vehicles, a substantial engine control module is provided thatperforms a wide range of functions. For example, the module providessignals via an electrical harness to various electrical componentsthroughout the engine and vehicle. In addition, the module receivessignals from a number of sensors disposed at various locationsthroughout the engine.

For example, as shown in FIG. 1, an engine control module (ECM) 10includes a housing 11 with a top mounting boss 12 and side bosses 13extending therefrom. The mounting bosses provide a means for mountingthe ECM 10 within the vehicle or engine compartment. The ECM 10 includesa number of electrical components and microprocessors within the housing11. A pair of connectors 17 are provided for engaging a pair of cablesor harnesses 18, 19. These cables 18, 19 link the electronic andmicroprocessor components of the ECM 10 to the various sensors andengine control devices.

These electronic control or engine control modules utilizemicroelectronic components mounted on a substrate. In one type of ECM10, a circuit board 20 is provided that includes a number of components21 mounted thereon (see FIG. 2). In one particular approach, the circuitboard 20 is formed of a flexible material, such as polyimide. Thecircuit board 20 is mounted to a rigidizer 15, which is formed of arelatively rigid substrate that is capable of withstanding the harshenvironment of the engine. With this ECM, the rigidizer material hasproperties that allow the rigidizer to be folded or bent. In oneexample, the rigidizer is formed of aluminum.

One particular rigidizer 15 is shown in FIG. 2. The rigidizer 15includes a top plate 16A, a bottom plate 16B and an integralintermediate bend region 16C between the two plates. The bottom plate16B defines a number of connecting holes 22, which receives a number ofscrews therethrough for attaching the connectors 17 to the outsidesurface of the bottom plate. A number of slots 23 are formed at the bendregion 16C of the circuit board 20 as a bend relief feature and toaccommodate a hinge support component of the housing 11, as describedherein. The rigidizer 15 also defines certain features for retaining andsupporting circuit board 20. For example, the rigidizer defines asealing or alignment rim 27 around the perimeter of the top plate 16Aand bottom plate 16B. The outer perimeter of the circuit board 20follows the contour of the sealing rim 27. Preferably, the circuit board20 is engaged to the rigidizer 15 with a compatible adhesive. Thesealing rim 27 is offset from the edges of the rigidizer 15 for reasonsmade clear herein. The rigidizer 15 also defines a plurality of housingmounting holes 25 that are used to receive a like number of screws 26(FIG. 1) for closing the rigidizer 15 about the housing 11 to form thesealed module 10. A number of mounting boss reliefs 24 can also bedefined around the edge of the rigidizer 15 to correspond to thelocation of the side mounting bosses 13 of the housing 11.

Details of the housing 11 are shown in FIG. 3. Like the rigidizer 15,the housing is preferably formed of a rigid metal, such as aluminum. Thehousing 11 is generally sized to correspond to half of the rigidizer 15,since the housing is disposed between the top plate 16A and bottom plate16B. Thus, the features depicted in FIG. 3 appear on both sides of thehousing 11. For example, the housing includes an outer rim 30 thatfollows the outer perimeter of the housing. An inner rim 31 is alsoformed in the housing offset inward from the outer rim. The inner rim 31corresponds to the configuration to the sealing rim 27 defined onrigidizer 15.

The housing 11 defines a number of connector holes 37 that align withthe corresponding mounting holes 22 in the circuit board 20 andrigidizer 15. A number of mounting holes 38 pass through the housing 11and are aligned with the housing mounting holes 25 to receive the screws26. The housing 11 also includes a number of hinge supports 35 that arealigned with the slots 23 formed in the circuit board 20. These hingesupports 35 are preferably rounded and provide a surface about which thebend portion 16C of the rigidizer 15 is folded.

As shown in FIG. 4, the housing 11 is sandwiched between the top plate16A and the bottom plate 16B of the rigidizer 15. A number of connectormounting screws 39 pass through the mounting holes 37 in the housing 11and the holes 22 in the bottom plate 16B to engage the connectors 17. Inthe construction of this module 10, the rigidizer 15 is bent around thehousing 11. The rigidizer 15 is configured to essentially sit within theouter rim 30 of the housing, as shown most clearly in FIG. 5. When therigidizer 15 is bent around the housing 11, the various rims, namely thesealing rim 27 of the rigidizer 15, and the outer and inner rims 30, 31of the housing 11, define a bead groove 33 that travels around threesides of the perimeter of the module 10. The bead groove 33 need notextend to the bend region 16C of the rigidizer 15, since that side oredge of the module 10 is already closed. Before the top plate 16A andbottom plate 16B of the rigidizer 15 are bent to their final position,an adhesive or sealant bead 40 is applied along the bead groove 33. Thissealant bonds the rigidizer 15 to the housing 11. Preferably, the beadmaterial is capable of bonding metal-to-metal, while withstanding thehigh temperatures experienced in the engine compartment. In oneembodiment, the bead is an RTV material.

While the ECM 10 depicted in FIGS. 1-5 provides an environmentally soundand sealed module, difficulties arise when the module must beremanufactured. This remanufacturing process may be required when thereis an update to some of the components 21 mounted on the circuit board20. In other instances, direct diagnosis of the components is necessary,necessitating access to the circuit board 20. In the absence ofremanufacturing, the ECM 10 is simply disposed of or scavanged, andreplaced with a new module. Of course, this approach unnecessarilywastes resources and can lead to delays where the module is difficult toobtain.

Consequently, there is a need for a system and method that permits theremanufacture of modules, such as the ECM 10 described above. The systemand method must be capable of opening the module without disturbing orcompromising the rigidizer 15, or the circuit board 20 and itscomponents.

SUMMARY OF THE INVENTION

In order to address these needs, the present invention contemplates asystem and method for opening a sealed module for remanufacture. In oneaspect of the invention, the housing is machined at its perimeter toexpose a sealing bead. The machining operation is precisely controlledto prevent any. impingement on the rigidizer or the circuit boardmounted on the rigidizer. Instead, only the housing is machined toprovide access to the bead groove. In a next step of the method, thesealing bead is disrupted substantially around the perimeter of themodule. In one embodiment, a slot saw is operated along the entireperimeter at the bead groove to cut a channel or slot along the sealingbead at both the top and bottom plates of the rigidizer. In anotherembodiment, an array of wedges is driven into the bead groove.

Once the sealing bead has been disrupted or weakened, the top plate andbottom plate can be unbent relative to each other. In one aspect of theinvention, a bending brake device is modified for opening the sealedmodule. In the preferred embodiment, the outer perimeter of both the topplate and the bottom plate of the rigidizer are fully supported in orderto maintain the integrity of the rigidifier and circuit board mountedthereon. Consequently in a further aspect of the invention, a system isprovided in which an opening fixture is used to support the plates ofthe rigidizer while facilitating the unbending operation. The openingfixture can include a fixed base portion having a flange configured tofit within the slot cut into the sealing bead at the bottom plate. Theflange extends substantially around the perimeter of the sealing beadgroove.

The fixture can also include a moveable or pivotable upper rigid supportthat also includes a flange configured to engage the slot formed in thesealing bead between the top plate and the housing. The upper perimetersupport is hingidly mounted to the base or lower perimeter support sothat the upper support can essentially pivot about the bend region ofthe rigidizer. The fixture can include a pair of moveable stops that aremoveable from one position clear of the lower perimeter support to allowinsertion of the module into the opening fixture and a second positionin which the stops block or prevent expulsion of the module from theopening fixture during the unbending process.

In one embodiment, the opening fixture is manually operated. With thisapproach, the upper perimeter support provides adequate surface forgrasping and pivoting about the hinge mount to unbend the rigidizer atthe bend region. In an alternative embodiment, the opening fixture ispowered. In this feature, the upper perimeter support includes a leverarm that is connected to a drive mechanism or power device. Forinstance, the drive mechanism can constitute a pneumatic or air cylinderin which the cylinder piston is connected to the lever arm.Reciprocation of the piston causes the lever arm to pivot about thehinge mount, which thereby causes the upper perimeter support to pivotabout the hinge.

With either opening fixture, the bottom plate is held generally rigidand unmovable while a force is applied to the top plate to unbend therigidizer about the bend region. Using this fixture, the integrity ofthe rigidifier is maintained, not only in the top and bottom plates, butalso at the bend region. A controlled force can be applied, eithermanually or automatically, to the upper perimeter support to graduallyopen the module. Preferably, at this point, the integrity of the sealingbead has been sufficient disrupted by the machined slot so that the beaditself offers little resistance to the separation of the rigidizer fromthe housing.

In a preferred embodiment, the top plate is unbent so that the top plateforms approximately a ninety-degree angle relative to the bottom plate.At this point, the housing can be removed by removing any fasteners thatmay be holding the housing to the bottom plate of the rigidizer. Thehousing can be discarded, since it has been significantly machined. Withthe housing removed, the perimeter of the rigidizer adjacent the sealingrim can be cleaned of any residual sealing bead material.

With the module thus opened, the components of the circuit board can bemodified, replaced and/or tested. The rigidizer and circuit board arenow ready to receive a new housing. In a further feature of theinvention, a handling support is provided to preserve the integrity ofthe rigidizer, and particularly the top and bottom plates, when theunbent or open rigidizer is removed from the opening fixture. In oneembodiment, the handling support includes an upper bar and lower barconnected at a substantially right angle joint. Each of the bars definesa groove to receive a side edge of one of the plates of the rigidizer.Each of the bars includes an opening to receive a fastener therethrough,which fastener is. aligned with one or more of the external fasteneropenings defined in the rigidizer. This handling support is thusconnected to the rigidizer to maintain the top and bottom plate in theirninety-degree orientation, and to preserve the structural integrity ofthe rigidizer and circuit board mounted thereon.

Once the work on the circuit board has been completed, the rigidizer iscarried by the handling supports to a closing fixture. The handlingsupports can then be removed and the rigidizer mounted within thefixture. In one embodiment of the invention, the rigidizer is orientedso that its top and bottom plates form a forty-five degree anglerelative to the horizontal. The new housing can then be inserted intothe space between the top and bottom plates and fastened to theappropriate plate. A new sealing or joint bead can be applied to boththe top and bottom plates around their perimeter adjacent the sealingrim. The closing fixtures can be operated to push the top and bottomplates toward each other, thereby bending the rigidizer at the bendportion with the housing sandwiched between the two plates. The closingfixture can be held in position with the rigidizer clamped about thehousing for sufficient period of time to allow the sealing or joint beadto cure. Upon completion of this step, a new remanufactured controlmodule is available for mounting within a particular vehicle.

It is one object of the present invention to provide a system and methodfor the remanufacture of the sealed electronic modules. A further objectof the invention is achieved by features that maintain the integrity ofthe circuit components of the module, while minimizing the number ofmodule components that must be replaced.

The present invention provides a significant benefit to systemsemploying a sealed module since the modules no longer need to bediscarded when errors arise or system updates are required. A furtherbenefit is that the remanufacture process does not require anycomplicated machines or fixtures, which means that remanufacturingstations can be readily and cheaply provided for a mass remanufacture ofsealed control modules.

These and other objects and benefits, will become apparent uponconsideration of the following written description and accompanyingfigures.

DESCRIPTION OF THE FIGURES

FIG. 1 is a side perspective view of an engine control module and itsconnection to various components of the vehicle.

FIG. 2 is a top elevational view of a rigidizer that forms one componentof the engine control module depicted in FIG. 1.

FIG. 3 is a top elevational view of a housing that is sandwiched betweenthe portions of the rigidizer shown in FIG. 2, to form the controlmodule illustrated in FIG. 1.

FIG. 4 is a front perspective view of the engine control module shown inFIG. 1 prior to final closing of the module.

FIG. 5 is a cross sectional view through one side of the engine controlmodule as depicted in FIGS. 1 and 4.

FIGS. 6A-6C are front perspective views of an engine control module atthree stages of the inventive process for opening the module.

FIG. 6D is a rear perspective view of the module machined as in theprevious steps, with the results of an additional step in the process.

FIG. 7 is a perspective view of the sealed module after completion ofthe sequence of steps depicted in FIGS. 6A-6D.

FIG. 8 is a rear top perspective view of an opening fixture inaccordance with one aspect of the present invention.

FIG. 9 is a side elevational view of the opening fixture shown in FIG.8.

FIG. 10 is front perspective view of the opening fixture depicted inFIGS. 8 and 9 with a control mounted within the fixture.

FIG. 11 is a side elevational view of an alternative embodiment of anopening fixture in accordance with the present invention in which thefixture is powdered.

FIG. 12 is a rear perspective view of the opening fixture shown in FIG.11 particularly showing stops for supporting the bend region of thesealed module.

FIG. 13 is a front perspective view of a rigidizer after it has beenunbent and the housing removed, with the rigidizer being maintained by apair of handling supports.

FIG. 14 is a side elevational view of one of the handling supportsdepicted in FIG. 13.

FIG. 15 is a side elevational view of the opened or unbent rigidizermounted within a closing fixture in anticipation of inserting a newhousing and a new sealing bead prior to closing.

FIG. 16 is a front perspective view of an alternative embodiment of theinvention in which an arrangement of wedges are used disrupt the sealingbeads around the perimeter of the rigidizer and housing.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

For the purposes of promoting an understanding of the principles of theinvention, reference will now be made to preferred embodimentsillustrated in the drawings and specific language will be used todescribe the same. It will nevertheless be understood that no limitationof the scope of the invention is thereby intended, such alterations andfurther modifications in the illustrated embodiments, and such furtherapplications of the principles of the invention as illustrated thereinbeing contemplated as would normally occur to one skilled in the art towhich the invention relates.

In one aspect of the invention, a sealed module, such as the sealedmodule shown in FIG. 6A, is manipulated to permit removal of the housing11. As shown in FIG. 6A, the outer rim 30 of the housing 11 essentiallyprotects the edges of the top plate 16A and bottom plate 16B (notshown). With the particular ECM 10 shown in this figure, the housingincludes a pair of side mounting bosses 13 and a top mounting boss 12that are configured to receive mounting bolts to support the modulewithin the engine compartment

In the next step of the invention, the housing is machined to remove theexternal features at the perimeter of the housing. More specifically,the housing 11 is machined to remove the outer rim 30, side mountingbosses 13 and top mounting boss 12. The purpose of this machining stepis to expose the side edge around the perimeter of the rigidizer 15, aswell as the sealing bead disposed between the top plate 16A and thehousing 11, and the bottom plate 16B and the housing. Preferably, thismachining step is performed using a mill machine. Most preferably, anumerically controlled milling machine is utilized to provide precisioncutting of the housing without affecting the rigidizer 15. It should beunderstood that the milling operation only occurs on three sides of themodule 10′ shown FIG. 6B. The back side of the module 10′ is closed bythe bend region 16C of the rigidizer 15. Since the goal is to maintainthe integrity of the rigidizer, no machining operation occurs on thatback side.

In the next step of the procedure depicted in FIG. 6C, the sealing bead40 that runs along the perimeter between the top plate and the house andthe bottom plate and the housing, are both disrupted. In the preferredembodiment, these two beads are disrupted by using a slot saw to cut aslot or groove 49 along the bead material and between the rigidizer 15and housing 11. Preferably the slot saw has a width substantially equalto the distance between the top plate 16A and the housing 11, forinstance. The slot saw can have a width and depth that correspondence tothe width and depth dimensions of the bead groove 33 (see FIG. 5)between the two plates of the rigidizer and the housing. Again, the slotsaw-can be numerically controlled to assure a precision cut that doesnot damage the rigidizer 15 or the circuit board 20 mounted on therigidizer. The object of this step is to substantially disrupt thesealing bead 40 to facilitate unbending of the rigidizer 15.

In certain embodiments of the inventive method, the thickness of therigidizer 15 may make the unbending process more difficult, or at leastrequire a greater amount of force than for a thinner plate. Thus, inthese embodiments an additional groove 50 is defined at the bend region16C of the rigidizer 15 as shown in FIG. 6D. This groove 50 acts as asort of hinge relief as force is applied to the top plate 16A. In thisinstance, this force will cause the top plate 16A to essentially pivotabout the hinge groove 50. It is understood that the hinge groove 50must not pass completely through the thickness of the rigidizer 15.Preferably, the groove has a depth of about one quarter of the thicknessof the rigidizer 15 at the bend region 16C. This interruption in therigidizer surface will lead to a measurable reduction in the amount offorce necessary to unbend the top plate 16A relative to the bottom plate16B.

Following completion of the process steps shown in FIGS. 6B-6D, themodified ECM 10′ appears as shown in FIG. 7. In the illustratedembodiment, the rigidizer 15 includes relief notches 24 defined in theside of the top and bottom plates to accommodate the side mountingbosses 13 and the housing 11.

In the machining step as illustrated in FIG. 6B, these mounting bossesare also removed, leaving the relief notches 24 of the rigidizer 15exposed as shown in FIG. 7.

The module 10′ can then be placed within an opening fixture, such as thefixture 60 as shown in FIGS. 8-10. The primary function of the fixture60 is to provide substantial support for the rigidizer 15 while allowingthe rigidizer to be pivoted or unbent about the bend region 16C. It isimportant that the integrity of the rigidizer 15 be maintainedthroughout the unbending process to ensure that the top and bottomplates 16A, 16B do not bow or flex. While the rigidizer itself caneasily withstand this deflection, the circuit board 20, as well as thecomponents and solder joints present on the board, cannot withstand anydegree of bowing of flexing. With this in mind, the opening fixture 60includes a base 61 onto which mounted a lower perimeter support 63. Thelower perimeter support 63 defines a flange 64 around three sides of itsperimeter. The flange 64 has a thickness and a depth that aresubstantially equal to the thickness and depth of the bead groove 33defined between the top and bottom plates and the rigidizer. In otherwords, the flange 64 is sized to fully support the perimeter of therigidizer 15 directly adjacent the sealing rim 27 (see FIG. 2).

The opening fixture 60 also includes an upper perimeter support 65 thatalso includes a similarly configured flange 66. As with the lowerperimeter support, the upper perimeter support and flange 66 areconfigured so that the rigidizer 15 is fully supported directly adjacentthe sealing rim 27.

The upper perimeter support 65 is mounted to the base 61 or lowerperimeter support 63 by way of a hinge mounting portion 69. In oneembodiment, the upper perimeter support can include a pivot boss 70 thatis engaged to the hinge mount portion 69 of the lower perimeter supportby way of a hinge pin 71. Thus, the upper perimeter support 65 ismounted for rotation or pivoting relative to the fixed lower perimetersupport 63.

The opening fixture 60 is configured so that the ECM module 10′ can beinserted in the direction of the arrow D. When the module is disposedwithin the fixture, some means are necessary for preventing the modulefrom backing out of the fixture when the bending force is being appliedby way of the upper perimeter support 65. Thus, in one embodiment, apair of stops 74 are included that are arranged to contact the rigidizer15 at the bend region 16C. Preferably the stops 74 are adjustable sothat they can be moved from a position blocking the opening to thefixture 60 as shown in FIG. 8, to a position in which the stops 74 areclear of the opening to allow insertion of a sealed module. In onespecific embodiment, the stops 74 can be slidingly mounted within acorresponding adjustment slot 75. A variety of configurations for theadjustment slot can be provided other than having the having the stops74 move transversely across the opening of the fixture 60. For example,the slots can be orientated in the direction of the arrow D, or at anyangle therebetween. Preferably the stops 74 are of a known constructionthat allows the stops to be loosened relative to the slot when it isdesired to move the stops and then retightened to fix the position ofthe stops relative to the slots 75.

The positioning of a module 10′ within the opening fixture 60 isdepicted in FIG. 10. As shown in the figure, the module 10′ is slid intothe opening fixture 60 with the top plate 16A being supported by theupper perimeter support 65. The bottom plate is not seen in the figurebut is situated under the lower perimeter support 63. In the instance inwhich the module 10′ includes connectors projecting below the bottomplate 16B, as illustrated in FIG. 1, the lower perimeter support 63 canbe offset relative to the base 61 to provide space for receiving theconnectors. With the module 10′ thus mounted within the opening fixture60, a force P can be applied to the upper perimeter 65 to rotate theupper support 65 relative the fixed lower support 63. As this rotationcontinues, the top plate 16A of the rigidizer 15 gradually unbends orpivots relative to the lower plate and ultimately relative to thehousing 11.

In the preferred embodiment, the upper perimeter support 65 is rotateduntil the top plate 16A forms a substantially ninety degree anglerelative to the bottom plate 16B. In this orientation, the housing 11,and most particularly the connector mounting screws 39, are cleanlyexposed. The housing 11 can be removed from the module 10′ by removingthe mounting screws 39, as well as any other fasteners that might beused to fix the housing 11 to the bottom plate 16B. Once the housing 11has been removed, the circuit board 20 mounted to the rigidizer 15 willbe fully exposed to allow the repair, replacement, or testing of thecomponents mounted on the circuit board.

In the embodiment illustrated in FIG. 10, the force P is manuallyapplied. The amount of manual force that needs to be applied to unbendthe rigidizer 15 depends upon the thickness of the rigidizer and thelever arm provided by the upper perimeter support 65. The upper supportcan be modified to include manually engageable features projectingoutward to the support to improve the pivoting fulcrum.

In an alternative embodiment, the opening process is automated orpowered. In this embodiment, an opening fixture 80 as shown in FIG. 11includes a base 81, a lower perimeter support 83 and an upper perimetersupport 85. The perimeter supports 83 and 85 each include a respectiveflange 84 and 86, and are otherwise configured similar to the supports63 and 65 as shown in FIG. 8. As shown in FIG. 11, the lower perimetersupport 83 is elevated to provide clearance for receiving the connectors17. The lower perimeter support 83 can be fixed to the base 81 by way ofa mounting assembly 93. The mounting assembly can consist of a bolt andflange arrangement, or other known means for fixedly mounting thesupport 83.

As with the previous embodiment, the upper perimeter support 85 ispivotally mounted relative to the lower support. Thus, the lower supportcan include a hinge mounting portion 89 and the upper support 85 caninclude a pivot boss 90. A hinge pin 91 can pivotably connect the twosupports. In addition, as with the previous embodiment, the openingfixture 80 includes a stop assembly 95 that is arranged to prevent themodule from backing out as the unbending force is being applied to therigidizer 15.

In contrast to the opening fixture 60, the opening fixture 80 includes alever arm 97 that extends outwardly from the upper perimeter support 85.In the preferred embodiment, the lever arm 97 extends downwardly througha slot 98 defined in the base 81. A drive mechanism 99 is supportedunderneath the base 81 and is connected to the lever arm 97. Themovement of the drive mechanism 99 in the direction of the arrow Tproduces a rotation of the support 85 in the direction of the arrow R.

Using this drive mechanism, manual manipulation or unbending of therigidizer is not required. This drive mechanism 99 can take a variety offorms, such as a pneumatic or hydraulic cylinder with a reciprocatingdrive shaft 100. Alternative powered drive mechanisms are contemplatedthat are capable of rotating the upper perimeter support 85 relative tothe hinge mount 89. For instance, an electric motor, a rack and pinionarrangement, a cam mechanism, or other drive mechanisms arecontemplated. Moreover, while the most preferred embodiment utilizes alever arm 97, the drive mechanism can be mounted to the upper perimetersupport 85 or pivot boss 90. The important feature to be retained is theability to provide a controlled unbending force to the upper perimetersupport 85, and consequently the rigidizer 15 mounted within the openingfixture 80. Preferably, the drive mechanism 99 includes an apparatus forcontrolling the operation of the mechanism so that the drive mechanism99 stops when the top plate 16A has reached a preferred angle relativeto the fixed bottom plate 16B.

Referred to FIG. 12, details of the stop assemblies 95 are shown. Inparticular, the stop assembly can include a stop mount 101 that is fixedto the base 81. Preferably, the stop mount has a height that issufficiently low to provide clearance for inserting the module into theopening fixture 80. Each stop assembly can also include a moveable stop102 that defines a slot 103. A clamping screw 104 extends through thestop mount 101 and the slot 103. Loosening the clamping screw 104 allowsthe moveable stop 104 to be translated upward into contact with the bendregion 16C of the rigidizer 15. Once the moveable stop is in position,the clamping screws can be tightened to firmly support the module withinthe opening fixture. Preferably the moveable stop 102 is positioned sothat it does not traverse the hinge groove 50 or otherwise impede theunbending of the top plate 16A about the bend region 16C.

As previously indicated, the rigidizer 15 is preferably unbent or openedso that the top plate 16A forms a substantially ninety degree anglerelative to the bottom plate 16B, as shown in FIG. 13. In thisconfiguration, the housing can be easily removed and access is readilyprovided to the circuit board 20 mounted on the rigidizer. Just asduring the unbending process, it is essential that the rigidizer 15 notbend or flex during the remanufacture process, to avoid placing stressto the circuit board 20 and its mounted components. Thus, in a furtherfeature of the invention, a pair of handling supports 110 are providedto maintain the rigidizer 15 in its unbent orientation. In the preferredembodiment, the handling support 110 includes an upper bar 111 and alower bar 112 integrally formed with a right angle joint 113. The upperand lower bars 111, 112 define a rigidizer groove 115 therein. Thegroove is sized to receive one of the plates of the rigidizer 15therein. A number of attachment screws extend through bores 118 in theupper bar 111 and lower bar 112. The attachment screws 117 are alignedwith openings already formed in the rigidizer 15, such as the housingmounting holes 25. Preferably, one end of the bores 118 passing througheach of the bars 111, 112 is threaded so that attachment screws 117 canbe directly threaded to and fixed within the handling support 110. Thehandling supports also include a bend relief 119 defined at the rightangle joint 113 to accommodate the bend region 16C of the rigidizer 15.

While the rigidizer and the circuit board are supported by the handlingsupport 110, the technician can perform whatever repairs, replacementsor diagnostics as may be necessary to the module circuitry. The handlingsupport 110 can then be used to transport the opened rigidizer to aclosing fixture such as a closing fixture 120 shown in FIG. 15. At theclosing fixture, a new ECM is created by adding a housing 11 to theopened rigidizer 15. In one embodiment, the closing fixture includes afixed mount 122 that supports the opened rigidizer. Preferably the fixedmount includes a moveable support plate 123 arranged to initiallysupport the top plate 16A of the opened rigidizer 15 at a substantiallyforty-five degree angle relative to the horizontal. The fixed mount 122also includes a support recess 124 within which the bend region 16C ofthe rigidizer rests. A second component of the closing fixture 120 isthe moveable support 126. The moveable support 126 includes a supportsurface 127 that is arranged to support the bottom plate 16B of therigidizer, again at a substantially forty-five degree angle relative tothe horizontal. The moveable support 126 is configured or powered tomove in the direction of the arrow d.

As in the operation of the closing fixture 120, a housing 11 can beplaced between the two plates of the rigidizer 15. At some point in theprocess, a joint dispensing nozzle 129 is used to apply a joint bead 130along the exposed perimeter of the top and bottom plates 16A, 16B. Thisjoint or sealing bead can be the RTV bead or any suitable metal-to-metaladhesive. Once the joint bead has been applied, the housing 11 can berotated in the direction of the arrow a and fastened to the lower plate16B as described above.

The two halves or plates 16A, 16B or the rigidizer 15 are pushedtogether by movement of the moveable support 126. In addition, thesupport plate 123 is preferably pivotably connected to the fixed mount122 so that both the top plate 16A and bottom plate 16B can move towardeach other in the direction of the arrow c. The support plate 123 can beseparately powered or can be connected to the moveable support 126 byway of a linkage so that translation of the moveable support 126 alsoleads to pivoting of the support plate 123. The movement of the moveablesupport 126 can be calibrated so that it stops when the rigidizer 15 isfirmly joined with the housing 11. The newly closed module can then beheld within the closing fixture 120 for a period of time to allow thesealing bead to cure. After the bead has had time to cure, the newlyremanufactured sealed module can be removed from the fixture 120 andinstalled in a vehicle.

In the preferred embodiment of the invention, the sealing bead isweakened or disrupted in a machining process, as depicted in FIG. 6C. Inan alternative embodiment, the bead can be disrupted using a series ofwedges, as employed by the opening fixture 140 shown in FIG. 16. Thefixture 140 can include a pair of side walls 142 a front wall 143 and arear wall 144. Each of the walls are preferably fixedly mounted to abase. In accordance with this embodiment, a set of wedges 146 arearranged in alignment with the sealing bead 40 between the top plate 16Aand rigidizer 15 and between the bottom plate 16B and the housing 11.The wedges are preferably attached to a pushing block 147. A lead screw148 is connected to the pushing block 147 and is threaded through anopening 149 within the side walls 142 and front wall 143.

As shown in FIG. 16, two lead screws 148 are arranged in the side walls,while three lead screws are situated in the front wall. The wedges areconfigured to penetrate the sealing bead 40, so that they are preferablybeveled at their leading edges. Rotation of the lead screws 148 moveseach pushing block 147 toward the sealed module. Further rotation of thelead screws pushes each of the wedges 146 into the sealing bead 40,thereby disrupting the bead. As shown in FIG. 16, the lead screws 148are configured to be manually rotated. However, the screws can besimultaneously driven by a series of rotary motors.

While the invention has been illustrated and described in detail in theforegoing drawings and description, the same is to be considered asillustrative and not restrictive in character, it being understood thatonly one preferred embodiment there of has been shown and described anthat all changes and modifications that come within the spirit of theinvention are desired to be protected. For example, the opening fixture60 can constitute a known bending brake that is modified to engage therigidizer. In addition, the opening fixture can be modified to providelimited perimeter support of the top plate 16A and bottom plate 16B whenthe substrate 15 is sufficiently rigid to avoid warping during theopening process.

What is claimed is:
 1. A fixture for opening a sealed module having ahousing and a substrate carrying a circuit board thereon and foldedaround the housing with a top plate adjacent a top face of the housingand a bottom plate adjacent a bottom face of the housing and a bendportion therebetween at one side of the housing, the module having anupper sealing bead between the top plate and the housing and a lowersealing bead between the bottom plate and the housing, the fixturecomprising: a fixed wall facing a portion of the perimeter of themodule; a pushing block; a drive mechanism connected between said fixedwall and said pushing block and operable to translate said pushing blockaway from said fixed wall toward the perimeter of the module; a firstwedge mounted on said pushing block and aligned to penetrate the uppersealing bead as the pushing block is translated toward the module; and asecond wedge mounted on said pushing block and aligned to penetrate thelower sealing bead as the pushing block is translated toward the module.2. The fixture for opening a sealed module according to claim 1 whereinsaid drive mechanism includes a lead screw coupled to said pushing blockand threadedly engaged through said wall.
 3. The fixture for opening asealed module according to claim 1 further including a number of saidpushing blocks and associated drive mechanisms positioned about theportion of the perimeter of the module.
 4. The fixture for opening asealed module according to claim 1 wherein the module has a front, aback and opposing sides; and wherein the fixed wall includes a firstportion facing the front of the module, a second portion facing one ofthe opposing sides of the module and a third portion facing the otheropposing side of the module; and further including at least one of anumber of said pushing blocks positioned between each of said first,second and third portions of said fixed wall and corresponding front andopposing sides of said module.
 5. The fixture for opening a sealedmodule according to claim 4 wherein said drive mechanism is connectedbetween said first portion of said fixed wall and one of said at leastone of a number of said pushing blocks, said drive mechanism configuredto translate said one of said at least one of a number of said pushingblocks away from said first portion of said fixed wall toward said frontof said module.
 6. The fixture for opening a sealed module according toclaim 4 wherein said drive mechanism is connected between said secondportion of said fixed wall and one of said at least one of a number ofsaid pushing blocks, said drive mechanism configured to translate saidone of said at least one of a number of said pushing blocks away fromsaid second portion of said fixed wall toward one of said opposing sidesof said module.
 7. The fixture for opening a sealed module according toclaim 6 wherein said drive mechanism is connected between said thirdportion of said fixed wall and another one of said at least one of anumber of said pushing blocks, said drive mechanism configured totranslate said another one of a number of said at least one of saidpushing blocks away from said third portion of said fixed wall towardthe other of said opposing sides of said module.
 8. The fixture foropening a sealed module according to claim 1 wherein the module has afront, a back and opposing sides; and wherein the fixed wall includes afirst portion facing the front of the module, a second portion facingone of the opposing sides of the module and a third portion facing theother opposing side of the module; and further including: a first drivemechanism connected between said first portion of said fixed wall and afirst one of said at least one of a number of said pushing blocks, saidfirst drive mechanism configured to translate said first one of said atleast one of a number of said pushing blocks away from said firstportion of said fixed wall toward said front of said module; a seconddrive mechanism connected between said second portion of said fixed walland a second one of said at least one of a number of said pushingblocks, said second drive mechanism configured to translate said secondone of said at least one of a number of said pushing blocks away fromsaid second portion of said fixed wall toward one of said opposing sidesof said module; and a third drive mechanism connected between said thirdportion of said fixed wall and a third one of said at least one of anumber of said pushing blocks, said third drive mechanism configured totranslate said third one of said at least one of a number of saidpushing blocks away from said third portion of said fixed wall towardthe other of said opposing sides of said module.